Tensioned Protective Equipment

ABSTRACT

A protective apparatus includes a helmet component and a mask component coupled to the helmet. The mask component includes at least one rigid component and at least one tensioned component coupled to the rigid component, the tensioned component forming a protective mesh.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 63/252,259 filed on Oct. 5, 2021, the entire contents of which are hereby incorporated by reference.

BACKGROUND

This specification relates to a protective equipment. For example, the protective equipment may include helmets or facemasks that can be worn by athletes in various sports, such as hockey, football, baseball, cricket, lacrosse or the like. Such equipment generally serves a purpose of protecting from impacts from either other participants or other equipment while maintaining the wearer's ability to see and participate to their fullest ability.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates an example protective facemask according to various embodiments of the disclosure.

FIG. 2A-2D illustrate example configurations of a protective facemask according to various embodiments of the disclosure.

FIG. 3A-3K illustrate example connections between tensioned and rigid components of a protective facemask according to various embodiments of the disclosure.

FIG. 4A-4F illustrate example configurations of a protective facemask according to various embodiments of the disclosure.

FIG. 5A-5D illustrate example configurations of tensioned components of a protective facemask according to various embodiments of the disclosure.

FIGS. 6A and 6B illustrate example protective facemasks according to various embodiments of the disclosure.

FIG. 7A-7E illustrate connections between components of protective facemasks according to various embodiments of the disclosure.

FIGS. 8A and 8B illustrate connections between components of protective facemasks according to various embodiments of the disclosure.

FIG. 9A-9C illustrate connections between components of protective facemasks according to various embodiments of the disclosure.

DETAILED DESCRIPTION

Protective equipment can be vital to the safety of individuals in various circumstances. For example, in many sports, there is a need to protect an athlete's face from potential injury. These sports include, among others, ice hockey, baseball, football, softball, lacrosse, and field hockey. Injuries can result from the athlete's face making contact with other athletes, balls, pucks, sticks, and bats. The protection provided by the facemask must be strong enough to bear impact without breaking or deflecting into the athlete's face. If required by a particular context, the openings in the facemask must also be small enough to prevent the ball, puck, stick, etc. from bypassing the facemask and making contact with the athlete's face. In addition to providing adequate safety, a secondary objective is to minimize the amount of material in front of the athlete's face, improving visibility and thereby improving the athlete's performance.

Some example apparatuses provide protection using a rigid network of bars. For example, these bars may be metallic rods welded together into a cage-like structure. The rigid structure is in turn rigidly mounted to the athlete's helmet or strapped to the athlete's face with padding between the bars and the face. Unfortunately, the bars may be thick to resist the impact and are, therefore, fairly restrictive of athlete visibility. Furthermore, they provide limited cushioning of the impact on their own, so any blow is transmitted without attenuation to the helmet.

Embodiments described herein provide protection with flexible material in place of the rigid bars. In some embodiments, the equipment operates as a net rather than that of a cage. Existing solutions resist impacts by loading the bars in bending or compression. In embodiments described herein, the impact is resisted by loading the flexible strings in tension. This allows for protection with reduced material thereby improving visibility. It also allows energy absorption, reducing the force of the impact transmitted to the athlete's head.

Described embodiments are generally directed toward face masks for athletic safety and performance, but may be used in general circumstances to improve safety or to protect other areas of an athlete. For example, protective equipment with flexible structures held in tension for support may be used for facemasks, over ear protection of helmets, chest or back pads, groin protection, limb protection, or the like. The tensioned structures may offer improved vision on facemasks, hearing on ear coverings, lighter equipment, or various other improvements over other structures.

The frame is the rigid portion of the facemask that gives it its shape and provides resistance for the strings to tension against, not unlike the rim of a tennis racket. It can be made of a variety of materials including metallic, such as steel or titanium, composite materials, such as carbon fiber or Kevlar™, plastic materials, or any other suitably stiff material. The frame may have any cross-sectional shape, including rectangular and circular. There might be holes, grooves, posts, hooks, or other such structures in or on the frame to guide the strings. The frame itself might be a braided composite, leaving holes for the strings to pass through.

Strings are held under tension across the frame. The strings are a tensioned component. as used herein refers to the category of flexible structures including thread, rope, tow, yarn, twine, cord, and cable. And possible materials could include aramid fibers like Kevlar, carbon fiber, glass fiber, synthetic polymers like nylon, Dyneema™, and Spectra™, natural fibers like flax, metallics like steel or titanium, or any combination of those materials and can be coated for aesthetic or durability. The facemask may consist of one structure or multiple structures.

The crossbar is an optional component of the facemask. If the geometry of the frame is such that the strings do not adequately clear the athlete's face, a crossbar may provide additional space for the athlete's comfort and safety. The crossbar is a rigid structure that creates a bridge over the athlete's face, lifting the strings away. It can be a single bar that is oriented horizontally, vertically, or at any angle in between. Or it can be a more complicated structure such as multiple rigid bars joined together, multiple rigid bars not joined together, or a bar or bars with protrusions. The crossbar can be made of a variety of materials including metallic, such as steel or titanium, composite materials, such as carbon fiber or Kevlar, plastic materials, or any other suitably stiff material. For example, the crossbar may be made of the same material as the frame. And like the frame, there might be holes, grooves, posts, hooks, or other such structures in or on the crossbar to guide the strings. The crossbar itself might be a braided composite, leaving holes for the strings to pass through. Even if the crossbar is not required to create more room for the athlete's face, it could still be required to tie the strings together, allowing them to work in unison to resist any impact to the facemask.

The strings may be connected to the frame or crossbar, either by passing through or looping through holes in the frame or crossbar or by passing over or looping around the frame or crossbar itself. The string may be looped around one or more times. In some embodiments, the strings may be retained in grooves or notches in the frame or crossbar. Optionally, at the intersection with the frame or crossbar, a string may be knotted to prevent slippage. A secondary structure of may also be employed to connect or retain the string to the frame or crossbar. This secondary structure could be a rigid clip, rigid hook, flexible loop, or the like. This secondary structure could be integral to the frame or crossbar or a separate component.

A string may also be knotted before or after passing through a hole or slot to create a stopper knot, a knot which prevents the string from sliding through the hole or slot. Alternatively, a secondary structure of any material may be glued, knotted, crimped, or otherwise attached to the string to fulfill the role of the stopper.

At the termination of the string, the string may be connected to itself, another string, the frame, or the crossbar. Connections may be made with knots or splices, or made with an adhesive or secondary mechanical connection like a wire rope clamp. Some possible examples of string terminations include: a knotted loop around the frame or crossbar, a large spliced loop held in position by the retaining features discussed above, or an adhesive connection directly to the frame or crossbar.

The frame and crossbar may be connected in a variety of manners. For example, first, the crossbar can be rigidly attached to the frame. Depending on the materials, they may be welded, glued, or fastened together directly or with a bracket or brackets. They may even be combined during the design phase and made as one piece. In some embodiments, the crossbar may be attached to the frame by means of a spring, dampener, or other cushioning structure. In some embodiments, the crossbar may be attached to the frame with a hinge-like structure. In some embodiments, the crossbar may not be directly attached to the frame at all. It can be attached indirectly by the strings and held in place under tension, in the manner of a tensegrity structure.

Tensioning of the strings maybe accomplished during the manufacturing process or with a tensioning structure that remains a part of the mask. Tensioning structures may include secondary mechanisms, like turnbuckles, or tensioning knots, like the versatackle knot. One or more tensioning structures may be used in any combination. The tensioning structure may directly or indirectly tension a string or strings in the facemask. For example, indirect tensioning might be used in embodiments in which the crossbar indirectly connects to the frame, forming a tensegrity structure; one string may be tensioned in a way that applies tension to the other strings in the facemask.

Depending on the pattern chosen for the strings, it is possible that strings will overlap or intersect. The strings may be allowed to pass over or under each other without any effort to join them together. The strings may be knotted together at the intersection, as they are in a net. In various embodiments, a variety of styles of knots would suffice. The strings may also be looped together. In addition to the basic loop patterns below, additional variations may be created by wrapping the string for more turns. Intersection may also consist of more than two strings, using any combination of the possibilities presented above.

Any pattern may be chosen for the strings to satisfy the requirements of adequate strength to absorb impact and, if required, adequate coverage to prevent a ball, stick, puck, etc. from making contact with the athlete's face. The pattern may include of one or more strings, of the same or different materials and thicknesses. A few examples of possible patterns are shown below. These examples are by no means exhaustive and only demonstrate the range of possibilities. Strings may begin or end on the frame, the crossbar, or other strings. In the figures below, the ends of the string(s) are shown as free ends and loops are exaggerated for clarity.

The method of mounting the facemask is dependent on the helmet that the mask is mounting to. At a mounting point, the facemask may need to mount fixedly or be able to be hinged. In both cases, this may be accomplished with a bracket made of metal, plastic, composite, or any other suitably stiff material or a strap made of a fabric, rubber, or plastic.

In some embodiments, the facemask may include additional components. For example, various padding elements, a chin cup, or other protective elements. Additional components may also include a visor to enhance vision in different lighting situations, electronic components for communication or monitoring, or any other components that do not interfere with the protective value of the facemask.

FIG. 1 illustrates an example protective facemask 100 according to various embodiments of the disclosure. The protective facemask 100 includes a frame 120, a crossbar 130 and strings 110. The protective facemask 100 is illustrated for example purposes as a facemask that may be used in conjunction with a helmet to provide protection for a hockey goalie. The general structure of the mask is provided for example purposes, and may in various embodiments of the present disclosure be modified to fit other mask designs. For example, a hockey goalie and forward may each desire a protective mask, however may have different designs based on the general risks of the position. Accordingly, in some embodiments, the facemask may not cover an entire face of a player, may cover the entire face, or may have different characteristics. Furthermore, the spacing of the strings 110 within the facemask may be dependent on the size of items, such as a hockey puck, that the facemask is to protect against. For example, if a hockey puck is 3 inches in diameter and 1 inch thick, the spacing of the strings 110 may be selected such that there are no gaps between the strings that could fit the hockey puck. In general, the configuration of the protective facemask 100 may be selected corresponding to a specific purpose, such as a particular sport, while being within the scope of this disclosure.

The frame 120 is a rigid component of the facemask that gives it shapes and provides resistance for the strings to tension against. The frame 120 may be made of a variety of materials including metallic, carbon fiber, plastic, or other materials that provide rigidity and strength to hold the strings 110 in tension.

The crossbar 130 is a rigid component of the facemask that provides additional shape and resistance for the strings 110 to tension against. For example, the crossbar 130 may provide additional shape to contour around a face when used by a user. In some embodiments, the crossbar 130 is made of the same rigid component as the frame 120. In some embodiments, the crossbar 130 and the frame 120 may be made of different materials.

The frame 120 and crossbar 130 may be made with a variety of cross sections, such as round, rectangular, ellipse, or another shape to provide sufficient strength to hold the strings 110. In addition, the frame 120 and crossbar 130 may include the same or different cross-sectional structures or may vary along their lengths. Furthermore, in some embodiments, the frame 120 and crossbar 130 may include holes or protrusions that aid in attachment of strings 110 as further described below.

The string 110 refers to a tensioned component of the protective facemask 100 that is held under tension between rigid components to provide a protective mesh or lattice. As descried the strings may include any flexible structure that can be pulled and fixed under tension between the rigid components. For example, the strings 110 may be comprised of one or more aramid fibers, carbon fibers, glass fibers, synthetic polymers, natural fibers, metallics, or the like. The strings 110 may include more than one material that works together to provide strength and flexibility as determined by the application.

FIGS. 2A-2D illustrate example configurations of a protective facemask 100 according to various embodiments of the disclosure. The protective facemask 100 includes a frame 120 and crossbar 130. Although not shown, the protective facemask 100 includes strings held under tension between the frame 120 and crossbar 130. FIG. 2A shows a protective facemask 100 with a horizontal crossbar 130 curved across the front of the facemask. FIG. 2B shows a protective facemask 100 with a vertical crossbar 130 across the front of the facemask. FIG. 2C includes a crossbar 130 with horizontal and vertical components curved across the front of the facemask. FIG. 2D includes a horizontal crossbar 130 with support structures. The protective facemask 100 shown in FIGS. 2A-2D are examples of potential configurations of crossbars 130 and frames 120, however, other configurations are contemplated within the scope of the disclosure.

FIGS. 3A-3K illustrate example connections between tensioned and rigid components of a protective facemask according to various embodiments of the disclosure. The examples illustrated in FIGS. 3A-3K show the connections between tensioned components of a protective facemask (strings 110) and rigid components of a protective facemask (frame 120). The connections are shown as examples and may be used for any connection between frame 120 and string 110 as well as for any connections between strings 110 and a crossbar (not shown). In some embodiments, a single connection type may be used for a protective facemask. In some embodiments, several connection types may be used together at different points of a protective facemask.

FIG. 3A shows a frame 120 connected to string 110 by means of holes 310. As shown in FIG. 3A, the string 110 passes through the holes in a continuous path. In some embodiments, the string 110 may terminate at the frame 120 with a knot securing the position of the string to the frame 120.

FIG. 3B shows a frame 120 with two possible sets of grooves 320A or 320B for securing the strings 110 to the frame. In some embodiments, grooves may have additional width to enable a string 110 to wrap around the frame 120. In addition to grooves as shown, other ridges, knots, or knobs may be formed on a frame 120 to secure a position of a string 110 or otherwise maintain its position on the facemask.

FIG. 3C shows a frame 120 connected to string 110 by means of holes 330. As shown in FIG. 3C, the string 110 passes through the holes in a continuous path. In some embodiments, the string 110 may terminate at the frame 120 with a knot securing the position of the string to the frame 120. As opposed to the holes 310 shown in FIG. 3A, the holes 330 shown in FIG. 3C have a different orientation with respect to the string 110.

FIG. 3D shows a frame 120 connected to string 110 by means of threading through a woven frame 120. For example, the frame 120 may be a woven Kevlar composite or another woven pattern of a rigid material. The strings 110 are connected to the frame 120 by threading through openings 340 in the structure of the frame 120.

FIGS. 3E-3I show connection to string 110 by securing around frame 120. In FIG. 3E, the string 110 is looped around the frame 120 by a single loop 350. In FIG. 3F, the string 110 is looped around the frame 120 by multiple loops 360. In some embodiments, additional loops may be used than shown in FIGS. 3E and 3F. In FIG. 3G, the string 110 is secured around the frame 120 with a single loop with a knot 370. In FIG. 3H, the string 110 is secured around the frame 120 with multiple loops with a knot 380. In some embodiments, additional loops or knots may be used to secure string 110 to frame 120. In some embodiments, the connections shown for rigid component of the frame 120 may alternatively or additionally be used to secure the string 110 to a crossbar. In FIG. 3I, the string 110 is secured around a knob 125 of the frame such that it is secured in position and continues on to another component of a frame or crossbar.

FIG. 3J shows a secondary structure that retains the string 110. In this example, this is a pin 397 and a sleeve 395, but this could be other structures that prevent the movement of a string 110 along a frame 120. For example, the secondary structure may include a single pin driven into the frame, a sleeve with a pin, a hose clamp, zip tie or other structures with frictional or mechanical connections to the frame 120.

FIG. 3K shows a frame 120 and string 110 connected in tension and held in place by a sleeve 385. The string 110 is looped between components of a frame 120 (or crossbar) and is held in place with the sleeve 385. A loop of string 110 is formed around the frame component and then pinched the middle together with a sleeve 385.

FIGS. 4A-4F illustrate example configurations of a protective facemask 100 according to various embodiments of the disclosure. FIGS. 4A-4F includes one or more strings 110, a frame 120, and in some embodiments a crossbar 130. The strings 110 may be connected to the frame 120 and crossbar 130 by means as described above with respect to FIGS. 3A-3H, or by other means that maintain tension of the strings 110 between the frame 120 and crossbar 130.

The pattern of the string 110, frame 120, and crossbar 130 of protective facemask 100 may be selected to provide adequate strength to absorb impact and coverage to prevent a ball, stick, puck, body part, or the like from contacting with the athlete's face. The pattern may comprise one or more strings 110 of the same or different materials. The examples shown are a subset of possible designs. In FIGS. 4A-4F, the strings 110 are shown with free ends and loops exaggerated for clarity while demonstrating the pattern. FIG. 4A illustrates a protective facemask 100 with a single string 110 routed in a pattern about the frame 120. FIG. 4B illustrates a protective facemask 100 with a single string 110 routed in a pattern about the frame 120 and a crossbar 130. FIG. 4C illustrates a protective facemask 100 with ten strings 110 routed through a frame 120 and crossbar 130. FIG. 4D illustrates a protective facemask 100 with four strings routed through a frame 120 and crossbar 130. FIG. 4E illustrates a protective facemask 100 with two strings routed through the frame 120 and crossbar 130.

FIGS. 5A-5D illustrate example configurations of tensioned components of a protective facemask according to various embodiments of the disclosure. The strings 110A and 110B in FIGS. 5A and 5B may be implemented in the embodiments discussed herein or other embodiments. FIG. 5A illustrates an example of intersecting strings 110A, 110B where the stings overlap at the intersection. FIG. 5B illustrates an example of knotted strings 110A, 110B where the strings overlap at an intersection. FIG. 5C illustrates an example of strings 110A, 110B looped at an intersection. FIG. 5D illustrates an example of strings 110A, 110B looped in another configuration at an intersection. The configurations shown in FIGS. 5A-5D may be implemented individually or in conjunction throughout application in a protective apparatus. In FIGS. 5A-5D intersections are shown at 90 degrees, but any angle may be used.

FIGS. 6A and 6B illustrate configurations of strings 110, frame 120, and crossbar 130 of a protective facemask 100. In FIG. 6A, the crossbar 130 is attached to the frame 120 by a coupling means as further described below. In FIG. 6B, the crossbar 130 is not directly attached to the frame 120, but is suspended by the strings 110 held under tension, wherein the shape, length, and tension of the strings 110 hold the crossbar 130 in position.

FIGS. 7A-7E illustrate possible coupling mechanisms between the frame 120 and the crossbar 130. In various embodiments, more than one coupling mechanism may be used in conjunction with others to generate the structure of the protective facemask. In FIG. 7A, the crossbar 130 is coupled to the frame 120 by means of a bracket 140. In FIG. 7B, the frame 120 and crossbar 130 are one piece or may be welded together. For example, the frame 120 and crossbar 130 may by one integrated piece. In FIG. 7C, the frame 120 and crossbar 130 are coupled by means of a spring or damper connection 160. In FIG. 7D, the frame 120 and crossbar 130 are coupled by means of a pin 170 between one or more holes of the frame 120 and crossbar 130. In FIG. 7E, the crossbar 130 has a fork holding the crossbar 130 in position with the frame 120.

FIGS. 8A and 8B illustrate connections between a helmet 200 and a protective facemask 100. In some embodiments, the strings 110 may be attached directly to the helmet 200 with the helmet 200 acting as a frame to hold the strings 110 in tension. In the embodiments illustrated in FIGS. 8A and 8B, the protective facemask 100 is connected to the helmet using a bracket or strap 180 and a fastener 190. In some embodiments, the strings 110 may be attached directly to the helmet 200 with the helmet 200 acting as a frame to hold the strings 110 in tension.

FIG. 9A-9C illustrate connections between a chin cup 220, a bracket 210, and a facemask 100. The chin cup 220 is provided as an example of an accessory that may be attached to a protective facemask as described herein. In some embodiments, the chin cup 220 and bracket 210 (or other accessory), may attached to the frame of a facemask in order to provide appropriate support.

The preceding description has been presented to illustrate and describe certain examples. Different sets of examples have been described; these may be applied individually or in combination, sometimes with a synergetic effect. This description is not intended to be exhaustive or to limit these principles to any precise form disclosed. Many modifications and variations are possible in light of the above teachings. It is to be understood that any feature described in relation to any one example may be used alone, or in combination with other features described, and may also be used in combination with any features of any other of the examples, or any combination of any other of the examples. 

What is claimed is:
 1. A protective apparatus comprising: a helmet component; and a mask component coupled to the helmet, the mask comprising: at least one rigid component; and at least one tensioned component coupled to the rigid component, the tensioned component forming a protective mesh.
 2. The apparatus of claim 1, wherein the rigid component comprises a first rigid component and a second rigid component, and the tensioned component is coupled between the first rigid component and the second rigid component.
 3. The apparatus of claim 1, wherein the tensioned component comprises a plurality of strings to form the protective mesh.
 4. The apparatus of claim 1, wherein the tensioned component comprises one or more of: aramid fibers, Kevlar, Dyneema, Spectra, carbon fiber, glass fiber, synthetic polymers, natural fibers, metal ropes, or cables.
 5. The apparatus of claim 1, wherein the rigid component comprises a frame and a crossbar, the frame defining a periphery of the mask and the crossbar oriented within the frame, wherein the tensioned component couples the crossbar to the frame.
 6. The apparatus of claim 1, wherein the tensioned component is coupled to the rigid component via at least one of holes, grooves, ridges, knots, or knobs.
 7. The apparatus of claim 1, wherein the protective mesh includes intersections of the tensioned components.
 8. The apparatus of claim 1, wherein the rigid component comprises at least one of: a metallic material, a composite material, or a plastic material.
 9. A protective mask comprising: at least one rigid component; and at least one tensioned component coupled to the rigid component, the tensioned component forming a protective mesh.
 10. The apparatus of claim 9, wherein the rigid component comprises a first rigid component and a second rigid component, and the tensioned component is coupled between the first rigid component and the second rigid component.
 11. The apparatus of claim 9, wherein the tensioned component comprises a plurality of strings to form the protective mesh.
 12. The apparatus of claim 9, wherein the tensioned component comprises one or more of: aramid fibers, Kevlar, Dyneema, Spectra, carbon fiber, glass fiber, synthetic polymers, natural fibers, metal ropes, or cables.
 13. The apparatus of claim 9, wherein the rigid component comprises a frame and a crossbar, the frame defining a periphery of the mask and the crossbar oriented within the frame, wherein the tensioned component couples the crossbar to the frame.
 14. The apparatus of claim 9, wherein the tensioned component is coupled to the rigid component via at least one of holes, grooves, ridges, knots, or knobs.
 15. The apparatus of claim 9, wherein the protective mesh includes intersections of the tensioned components.
 16. A protective apparatus comprising: a helmet component; and a mask component coupled to the helmet, the mask comprising at least one tensioned component coupled to the helmet component, the tensioned component forming a protective mesh.
 17. The apparatus of claim 16, wherein the tensioned component comprises a plurality of strings to form the protective mesh.
 18. The apparatus of claim 16, wherein the tensioned component comprises one or more of: aramid fibers, Kevlar, Dyneema, Spectra, carbon fiber, glass fiber, synthetic polymers, natural fibers, metal ropes, or cables.
 19. The apparatus of claim 16, wherein the protective mesh includes intersections of the tensioned components.
 20. The apparatus of claim 16, wherein the tensioned component is coupled to the helmet via at least one of holes, grooves, ridges, knots, or knobs. 